Turkey breast defatter

ABSTRACT

An automated poultry defatting apparatus which includes a housing having a product feed inlet and discharge outlet and housing a conveyor aligned to engage the upper surface of a piece of poultry product entering the feed inlet. The apparatus is provided with upper and lower peeling members for engaging the upper and lower surfaces of the poultry product passing between the conveyor and the peeling members. The peeling members have a plurality of grooved rollers that rotate in a cooperative manner to pinch and pull fat off the product while leaving the underlying muscle intact. The conveyor is pivotably mounted to the housing to permit automatic adjustment to a range of sizes of poultry product while maintaining a controlled downward force against the product to maintain firm engagement with the peeling members.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.12/188,354 filed Aug. 8, 2008.

STATEMENT REGARDING FEDERALLY-SPONSORED RESEARCH AND DEVELOPMENT

(Not Applicable)

REFERENCE TO AN APPENDIX

(Not Applicable)

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to defatting devices and moreparticularly to a device for removing the fat from sectioned pieces ofpoultry, such as, for example, turkey breasts.

2. Description of the Related Art

Over the past several decades, the defatting of pieces of poultryproduct, and turkey breasts in particular, has largely been performedmanually, which requires skilled labor. Even with a properly trainedworkforce, however, the defatting process has historically beenassociated with the potential for accidental injury, relatively lowproduct yields, a significant labor cost, and a certain level ofinconsistency of performance naturally attendant with any manual choreof this type.

It is therefore desirable to have means for efficiently defatting piecesof poultry product, and particularly turkey breasts, for maximizingproduct yields and consistency while minimizing production costs and therisk of accidental injury.

BRIEF SUMMARY OF THE INVENTION

The present invention relates to an automated poultry defattingapparatus which effectively and efficiently removes the fat from piecesof poultry product in a manner which does not significantly damage orwaste the underlying meat portions of the product.

The apparatus of the present invention preferably includes a base, ahousing, a feed inlet and discharge outlet, and a defatting stationmounted to the base and the housing intermediate the inlet and theoutlet. The defatting station preferably includes an endless belt-typeconveyor which is mounted to the housing in a vertically movablerelationship for both advancing poultry product along the defattingstation and applying a controlled pressure on the product against upper,lower, and peripheral peeling members mounted adjacent and below theconveyor. Each peeling member incorporates a plurality of peel rollersthat rotate in a cooperative manner to pinch the external fat on thepoultry product. Each roller is preferably provided with a plurality ofelongated, helical grooves in its outer surface that form “lands” orridges therebetween that are configured to entrap and efficiently pullthe fat away from the rest of the poultry product as the rollers rotate.This combination of structures cooperates to assure that the vastmajority of the fat is effectively peeled away from various musclesections of the product while the underlying meat (muscle) isessentially unaffected, rather than attempting to cut or slice the fatfrom the underlying meat.

Therefore, it is an aspect of the present invention to provide a poultrydefatting apparatus which effectively and efficiently pulls the externalfat from the underlying meat portion of the poultry product whileavoiding ripping or tearing of the underlying meat of the product.

It is another aspect of the present invention to provide a method ofdefatting a poultry product wherein the fat of a piece of poultryproduct is engaged and trapped under a controlled degree of pressure orforce to cause the fat to be peeled from the whole piece of poultryproduct without significant damage to the underlying meat.

It is another aspect of the present invention to provide an apparatus ofthe type described having the advancing conveyor pivotably mounted tothe housing for allowing the forward end of the of the conveyor toautomatically adjust to receive the poultry product within a range ofdifferent sizes while maintaining a downward force within a selectedrange on the piece of poultry product against the peeling members.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a perspective view illustrating the preferred embodiment ofthe present invention.

FIG. 2 is a top view illustrating the preferred embodiment of thepresent invention shown in FIG. 1.

FIG. 3 is a perspective view illustrating the preferred embodiment ofthe present invention shown in FIG. 1 with the front, side, and topportions of the housing removed for clarity.

FIG. 4 is a detail view illustrating the rear discharge outlet of thepreferred embodiment of the present invention shown in FIG. 1.

FIG. 5 is a detail view illustrating a peel roller of the preferredembodiment of the present invention shown in FIG. 1.

FIG. 6 is a schematic, end view illustrating the peel rollers of thelower peeling member of the preferred embodiment of the presentinvention shown in FIG. 1.

FIG. 7 is a front view illustrating the preferred embodiment of thepresent invention shown in FIG. 1 with the front, side, and top portionsof the housing removed for clarity.

In describing the preferred embodiment of the invention which isillustrated in the drawings, specific terminology will be resorted tofor the sake of clarity. However, it is not intended that the inventionbe limited to the specific term so selected and it is to be understoodthat each specific term includes all technical equivalents which operatein a similar manner to accomplish a similar purpose. For example, theword connected or terms similar thereto are often used. They are notlimited to direct connection, but include connection through otherelements where such connection is recognized as being equivalent bythose skilled in the art.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1-3, a defatting apparatus 10 in accordance with thepresent invention is illustrated. The apparatus is for removing fat frompieces of poultry product, and turkey breasts in particular. Theapparatus 10 includes a housing, indicated generally at 12, which ismounted to a base, indicated generally at 14, for conveniently locatingthe apparatus and the auxiliary product and fat collection means in themost practical arrangement for a given plant production layout.

For the sake of convenience and clarity, terms such as “front,” “rear,”“top,” “bottom,” “up,” “down,” “inwardly,” “outwardly,” “lateral,” and“longitudinal” will be used herein to describe the relative placementand orientation of various components of the invention, all with respectto the geometry and orientation of the defatting apparatus 10 as itappears in FIG. 1. Said terminology will include the words specificallymentioned, derivatives thereof, and words of similar import.

The housing 12 includes sidewalls 16 and 18 (sidewall 18 is not visiblein FIG. 1), a top wall 20, a front wall 22, and a rear wall 24. Thehousing 12 is mounted to the top of the base 14 in any conventionalmanner well-known to those of ordinary skill in the art, such as bywelding or by removable fasteners. The housing 12 has an angled, frontalopening intermediate the front wall 22 and the sidewall 16 to provide aproduct feed inlet 26.

As illustrated in FIG. 2, a chute 27 is employed to accept product anddeliver it by gravity through the feed inlet 26 and to the defattingstation, indicated generally at 28 in FIG. 3. However, alternative meansfor conveying product through the feed inlet 26, such as by aconventional belt conveyor, may be employed to deliver the product tothe defatting station 28 without departing from the present invention. Apartial entry wall 30 is desirably included intermediate the front wall22 and the sidewall 16 to define the upper extent of the feed inlet 26,and, in cooperation with the top wall 20, to partially enclose thedefatting station 28 to reduce contact with airborne contaminants and toprevent workers from extending their hands into the defatting station28.

Referring to FIG. 4, a rear discharge outlet 32 in the base 14 allowsdefatted poultry product to fall by gravity to a separate collectionarea relative to the removed fat once the poultry product has passedthrough the defatting station 28. The separate collection area for thedefatted product may be a conventional bin, or a conveyor 34, as shownin FIGS. 1 and 2. A central discharge outlet in the base (not withinview) is located directly below the defatting station 28 for allowingremoved fat to fall by gravity to a collection area such as a waste bin.

Referring to FIGS. 3 and 4, the defatting station 28 includes lower,upper, and peripheral peeling members, indicated generally at 36, 38,and 39 respectively, and an endless belt conveyor 40. The lower peelingmember 36 includes four elongated, substantially cylindrical peelrollers 42 that are arranged in a parallel, close-clearance relationshipon a common plane that is substantially parallel to the top plate 14 aof the base 14. Each of the peel rollers 42 has a plurality ofelongated, helical grooves 44 formed in its outer surface (see FIG. 5)forming a sharp land at the juncture of each adjacent pair of grooves.The rollers 42 extend longitudinally above the central discharge outletand are rotatably mounted to front and rear brackets 46 and 48. Thefront and rear ends of each roller are rotatably mounted to the brackets46 and 48, such as by mounting in conventional replaceable bearings, forallowing each roller to rotate freely about its own axis. The rollers 42are thus mounted to the base 14 through the brackets 46 and 48.

Although the lower peeling member 36 is described and shown as havingtwo pairs of peel rollers, it is contemplated that the peeling member 36can incorporate only one pair, or as many or as few pairs of rollers asare deemed necessary to accommodate a particular application. Whilespatial limitations may dictate the overall size of the peeling member36, and therefore the size and the quantity of the rollers 42, it hasbeen found that rollers having a diameter in the range of about 1.25inches to about 1.5 inches achieve the best results. However, peelrollers of any practical diameter are contemplated, as will beunderstood by those skilled in the art.

Gear teeth (not visible in FIGS. 3 and 4) are formed coaxially with theouter surface thereof at one end of each of the peel rollers 42 andoperatively engage the gear teeth of the adjacent roller or rollersthereby forming a drive mechanism. One of the rollers, herein referredto as the “drive roller,” additionally includes a coaxial drive sprocket(not shown) that extends radially from adjacent the roller's front end.The drive sprocket is preferably formed on an extension of the driveroller that extends longitudinally beyond the front bracket 46 into abearing 42 a. A chaindrive, described below, drives the drive roller 42,which drives the adjacent rollers 42, through the engaged gear teeth.

The upper and peripheral peeling members 38 and 39 are substantiallyidentical to the lower peeling member 36. The peripheral peeling member39 is mounted to the base plate 14 a adjacent to, and is generallycoplanar with, the lower peeling member 36. The upper peeling member ismounted to the base plate 14 a with its plane forming an angle relativeto the plane of the lower peeling member 36, thereby forming a V-shapedcrotch 37 between the peeling members 36 and 38. The angle between theupper and lower members is preferably about 30 degrees for effectivelyaccommodating most sizes of turkey breasts, although any angle in arange of about 15 degrees to about 45 degrees is contemplated. Like thelower peeling member 36, the upper and peripheral peeling members 38 and39 include a series of peel rollers 52 and 53, respectively, havinggears that are meshed with one another, including drive rollers withdrive sprockets in bearings 52 a and 53 a, respectively. Alternatively,it is contemplated that the gear teeth of the rollers 52 and 53 engagethe gear teeth of the rollers 42 so that one drive roller drives allpeel rollers. It is preferred that the peel rollers 53 of the peripheralpeeling member 39 have smaller diameters than the rollers 42 and 52 ofthe lower and upper members 36 and 38, and particularly within a rangeof about 0.75 inches to about 1 inch, for effectively engaging arelatively small area of the poultry product that passes through thedefatting station 28, as described in greater detail below.

Referring now to FIGS. 1 and 7, an enclosure 54 is mounted to theunderside of the base plate 14 a below the front ends of the peelingmembers 36, 38, and 39 that houses a drive system for rotatably drivingthe drive sprockets of the peeling members 36, 38, and 39. The drivesystem can be any type of conventional drive system, such as acombination of a conventional electric motor, a conventional series ofsprockets or pulleys, and drive chains or belts as described in U.S.Pat. No. 6,264,542 to Gasbarro, which is herein incorporated byreference.

When the drive system is actively rotating the drive rollers of thepeeling members 36, 38, and 39 via the drive sprockets, the engagementbetween the gear teeth of the peel rollers 42, 52, and 53 causes therotational movement of each drive roller to rotatably drive the adjacentrollers of the respective peeling members. For example, if one of thedrive rollers is rotated in a clockwise direction, the rollersimmediately adjacent the drive roller will each be driven in acounterclockwise direction. The next furthest roller or rollers from thedrive roller will thus be driven in a clockwise direction. In summary,each of the peel rollers rotates in a direction opposite that of theroller or rollers immediately adjacent it and which is driven by acommon drive chain or belt. This causes some pairs of adjacent rollersto have a pinching action on the upper surface thereof.

To further illustrate the operation of the rollers, a schematic end viewof the peel rollers 42 of the lower peeling member 36 is shown in FIG.6. The configuration of the four rollers, described above, results intwo pairs of adjacent rollers 56 and 58 having surfaces thatcooperatively rotate toward one another (as viewed from above, and asindicated by the horizontal arrows), and in a generally downwarddirection between the rollers (as viewed end-on, and as indicated by thevertical arrows) away from poultry product pieces that pass above therollers. Each pair of rollers 56 and 58 thus forms a pinch point that,in combination with the lands on the grooved surfaces of the rollers,allows the rollers to cooperatively entrap and pull fat off the poultryproduct. The size of the gap between adjacent rollers is exaggerated inFIG. 6, and actually amounts to either a small gap, or only a gap wheregroves exist, but none where aligned lands of adjacent rollers contacteach other.

After the fat is initially caught in the aligned grooves between therollers, the longitudinally-aligned lands between the helical grooves 44on the rollers 42 cooperatively grip the fat to provide a continuous,uninterrupted pulling force to efficiently strip the fat from theproduct and direct the fat between each pair of rollers 56 and 58 andaway from the product. Due to the gelatinous, malleable consistency ofpoultry fat and the relatively weak adherence of the fat layer to theunderlying meat of the poultry product, the fat can be effectivelytrapped in the facing grooves 44 of the rollers 42 and pulled away fromthe muscle of the product while the firmer, less malleable muscle isleft substantially intact to pass along the rollers to the reardischarge outlet 32. The fat is thereafter allowed to fall by gravityfrom the rollers through the central discharge outlet and into a wastebin.

It is preferred that both the width and the depth of the helical grooves44 are about 0.125 inches for optimal performance of the peeling members36, 38, and 39, although all other practical dimensions are contemplatedas will be understood by those skilled in the art. For example, grooveshaving any depth and width in a range of about 0.05 inches to about 0.25inches are generally acceptable.

While it is highly preferred that the peel rollers 42, 52, and 53 of thelower, upper, and peripheral peeling members 36, 38, and 39 are formedwith helical grooves 44 as shown in FIG. 5, it is contemplated that therollers 42, 52, and 53 can alternatively incorporate any other type ofsurface feature that would be effective for trapping and grippingpoultry fat by frictional engagement in the manner described above, suchas various forms of depressions, protrusions, or textures. For example,an embodiment of the invention is contemplated wherein the peel rollershave straight, longitudinal grooves, such as on a spline shaft. Anotherembodiment is contemplated in which the rollers have spiked protrusions.Yet another embodiment is contemplated wherein the rollers havehigh-friction, abrasive surface textures.

A water spraying member (not within view) is mounted to the interiorsurface of the housing 12 for directing a substantially continuoussupply of pressurized water to the peeling members 36, 38, and 39 and tothe product. The spraying member can be any type of conventional waterspraying system, such as a combination of manifolds and water supplyhoses that are mounted to the housing 12 in a longitudinal series. Thewater provided by the spraying member cleans the product as it is beingdefatted and lubricates and cleans the peel rollers 42, 52, and 53.

Referring to FIGS. 3 and 7, the belt conveyor 40 is mounted on aconveyor support arm 60 which in turn is mounted to the rear wall 24.The conveyor 40 is pivotably coupled to the support arm 60 in avertically movable relationship which allows the space defined betweenthe lower run of the belt 62 and the top of the lower peeling member 36to automatically adjust to, and receive, a selected range of differentsizes of poultry product pieces. The lower run of the belt 62 is angledrelative to the top of the lower peeling member, as best shown in FIG.7, for maintaining a substantially constant downward and lateralpressure or force on the poultry piece for biasing the piece toward thecrotch 37 formed at the intersection of the planes of the lower andupper peeling members 36 and 38, thereby keeping the lower and uppersurfaces of the poultry piece in firm engagement with the peelingmembers 36 and 38. In addition to applying a downward and lateral forceto the poultry product, the endless belt conveyor 40 functions totransport the product entering the feed inlet 26 longitudinally alongthe length of the peeling members 36 and 38 to the rear discharge outlet32 by also applying a longitudinal force. The belt 62 is provided with aplurality of fins 64 for gently and effectively propelling the poultryproduct along the length of the rollers 42 while minimizing the risk ofgouging, tearing, or piercing the meat.

A conventional electric motor 66 is mounted to the rear wall 24 adjacentthe conveyor support arm 54 for driving the conveyor 40 via a driveshaft 68. The motor 66 can be fixedly or adjustably mounted to the rearwall 24 in any conventional manner that will be appreciated by thoseskilled in the art, such as by a bracket 64, as shown in FIG. 7. Theconveyor 40 is thus supported by the conveyor support arm 60 and thedrive shaft 68 and is pivotably mounted to both structures for allowingthe forward end of the belt conveyor 40 to pivot freely about the axisof the drive shaft 68. A stop (not shown) in the form of a bolt or a pinis mounted to the inner side of the support arm 60 for engaging therearmost portion of the belt conveyor 40 to function as a limit to theextent of downward pivoting of the forward end of the conveyor 40, whichthus defines the predetermined separation or space between the lower runof the belt 62 and the top surface of the lower peeling member 36 whenthere is no product disposed therebetween.

Upon a piece of poultry product entering the feed inlet 26 and engagingthe belt conveyor 40, any product that is larger than the predeterminedspace will cause the forward end of the conveyor 40 to pivot upwardlyabout the axis of the drive shaft 68. If desired, another stop can beemployed in a similar fashion to the stop described above for limitingthe degree of upward pivoting by the forward end of the conveyor 40 to apredetermined level.

An important feature of the present invention is the above-describedrelative vertical movement between at least the forward portion of thebelt conveyor 40 aligned with the peeling members 36 and 38 to permit arange of sizes of poultry product to pass through the defatting stationwith a controlled range of angular pressure or downward force beingapplied to the piece of poultry for a given size range of product. Inthe preferred embodiment shown, the force applied to the piece ofpoultry engaging the peeling members 36 and 38 is set by the weight ofthe belt conveyor arrangement. This weight can be adjusted bycontrolling the initial weight of the arrangement or by adding weightsto the forward end in any conventional manner in the event that moreweight is deemed appropriate to accomplish the requisite level ofdownward force. It is important to note that too much applied force onthe poultry product is undesirable, as excessive force can cause tearingor gouging of the meat portions of the product upon engagement betweenthe conveyor 40 and the peeling members 36 and 38.

While other forms of mounting the belt conveyor 40 to apply a controlledamount of angular force and adjust automatically to different sizes ofproduct may be employed without departing from the spirit of the presentinvention, the free pivoting action of the preferred embodiment issimple, inexpensive, and has been shown to work very well. However,those of ordinary skill, in view of the disclosure herein, willrecognize that one could employ alternative means such as a piston andcylinder arrangement to movably adjust the distance between the lowerrun of the belt conveyor 40 and the peeling members 36 and 38, forexample, in response to the size of the poultry piece to accomplish asimilar function. Alternatively, such a pneumatic or hydraulic ram canbe used to apply downward pressure on the poultry piece.

During typical operation of the defatting apparatus 10 for removing thefat from a conventional turkey breast, the breast is placed on the chute27 and is allowed to fall by gravity through the feed inlet 26. Uponentering the defatting station 28, the upper surface of the turkeybreast is engaged by the angled belt conveyor 40. Because the belt 62tends to draw the poultry product beneath it, the belt conveyor 40automatically raises, if necessary, to accommodate the size of thebreast. The angle of the belt 62 also biases the breast toward thecrotch 37 formed near the lower and upper peeling members 36 and 38. Asthe conveyor 40 directs the breast from the front of the defattingstation 28 toward the rear discharge outlet 32, the lower, upper, andperipheral peeling members 36, 38, and 39 catch small tips of fat andstrip the fat from different portions of the breast. Specifically, thelower peeling member 36 removes a generally large amount of fat locatedon the underside of the breast lobe; the upper peeling member 38 removesa generally moderate amount fat located on the shoulder section of thebreast lobe; and the peripheral peeling member 39 removes a generallysmall amount of fat located on the tail end of the breast lobe. Thewater provided by the water sprayer washes residual pieces of fat offthe product and the peel rollers 36, 38, and 39. All of the removed fatfalls by gravity through the central discharge outlet and is collectedin a waste bin below.

After the defatted turkey breast reaches the rear end of the peelingmembers 36 and 38, the breast falls by gravity off the lower peelingmember 36 and through the rear discharge outlet 32. The breast thenfalls a short distance to the conveyor 34, which directs the breast intoa separate product collection bin where the breast can be collected forfurther processing.

Although the upper and peripheral peeling members 38 and 39 are includedin the preferred embodiment of the invention, it is contemplated thatone or both of the upper and peripheral members 38 and 39 can beomitted. If the upper member 38 is omitted, the belt conveyor 40 can bemounted to the rear wall 24 with the lower run of the belt 62 in aparallel orientation with the top of the lower peeling member 36 forproviding only a downwardly directed force or pressure on the poultryproduct. Alternatively, it is contemplated that a sidewall or otherbarrier can be substituted for the upper peeling member 38, in whichcase the conveyor 40 can be mounted at an angle, as in the preferredembodiment, for directing the product into a crotch formed between thelower peeling member 36 and the sidewall.

If the peripheral peeling member 39 is omitted, it is contemplated thatthe width of lower peeling member 36 may be increased by incorporatingadditional pairs of lower peel rollers for removing fat from the tailend of a turkey breast lobe.

This detailed description in connection with the drawings is intendedprincipally as a description of the presently preferred embodiments ofthe invention, and is not intended to represent the only form in whichthe present invention may be constructed or utilized. The descriptionsets forth the designs, functions, means, and methods of implementingthe invention in connection with the illustrated embodiments. It is tobe understood, however, that the same or equivalent functions andfeatures may be accomplished by different embodiments that are alsointended to be encompassed within the spirit and scope of the inventionand that various modifications may be adopted without departing from theinvention or scope of the following claims.

1. An automated poultry product defatting apparatus comprising, incombination: a) a housing mounted to a base and provided with a productfeed inlet and a product discharge outlet; b) a lower peeling membermounted to the base intermediate the feed inlet and the dischargeoutlet, the lower peeling member including at least one pair ofsubstantially circular, cylindrical lower peel rollers, each lower peelroller aligned in a substantially parallel orientation and in aclose-clearance relationship to the adjacent lower peel roller, whereinthe lower peel rollers rotate in a cooperative manner directly againstexternal fat on the lower side of a piece of poultry product placed onthe lower peel rollers, and thereby pinch the fat between the lower peelrollers to pull the fat off the poultry product; and c) a conveyormounted to said housing and aligned to engage an upper surface of thepiece of poultry product delivered to the feed inlet and direct theproduct in a path along, and in firm engagement with, the lower peelingmember toward the discharge opening, the conveyor being mounted forselected movement of at least a first end of the conveyor in response tothe size of the piece of poultry product.
 2. The automated poultryproduct defatting apparatus in accordance with claim 1, wherein each ofthe lower peel rollers has a plurality of grooves formed in its outersurface.
 3. The automated poultry product defatting apparatus inaccordance with claim 2, wherein the grooves are helical in shape. 4.The automated poultry product defatting apparatus in accordance withclaim 1, further comprising a peripheral peeling member mounted to thebase adjacent the lower peeling member and having at least one pair ofperipheral peel rollers, each peripheral peel roller aligned in asubstantially parallel orientation and in a close-clearance relationshipto the adjacent peripheral peel rollers, the peripheral peel rollersrotating in a cooperative manner to pinch external fat on an end of thepiece of poultry product between the peripheral peel rollers and to pullthe fat off the poultry product.
 5. The automated poultry productdefatting apparatus in accordance with claim 4, wherein each of theperipheral peel rollers has a plurality of grooves formed in its outersurface.
 6. The automated poultry product defatting apparatus inaccordance with claim 5, wherein the grooves are helical in shape.